Apparatus for removing residual developer material from a surface of a printing machine

Abstract: A cleaning apparatus for removing residual developer material remaining on a surface of a printing machine (Fig 3) is provided. The cleaning apparatus includes a movable cleaning brush (104) naving bristles. The brush (104) is positioned adjacent to the surface so that as the movable brush (104) is moved, the bristles contact the surface and the residual developer material is removed therefrom. A detoning device (200) is positioned adjacent to the movable cleaning brush (104) in a manner that permits the bristles to contact the detoning device (200) as the movable cleaning brush (104) is moved. The detoning device (200) includes a plurality of hook-like and/or teeth-like members (204: Fig. 7) which dislodge the residual developer material from the bristles as they contact the hook-like members.

Description: The present invention relates generally to a cleaning apparatus for removing residual developer material remaining on a surface of a photoreceptor of for printing machine, and, more specifically, to a detoning apparatus which facilitates removal of adherent developer material and developer material additives from the bristles of a cleaning brush. In electrophotographic applications such as xerography, although a preponderance of the toner forming the image is transferred to the paper during a transfer operation, some toner invariably remains on the charge retentive surface, it being held thereto by relatively hign electrostatic and/or mechanical forces. A commercially successful mode of cleaning employed in automatic xerography utilizes a brush with soft fiber bristles to remove residual toner particles from the charge retentive surface. US-A-3,842,273 discloses an apparatus for cleaning a corona generator. The corona generator includes a shield, a portion of which is preferably cleaned with a movable brush. In one example the brush is constructed with hook-like members. US-A-5,153,642 is directed toward a fiber cleaning system for a development system. The fiber cleaning system, which includes a plurality of hook-like members mounted on a support, is installed removably in a development station. In operation, developer material flows through the hook-like members so that contaminants are trapped thereby. Even for those circumstances in which toner is effectively removed from the photoreceptor with one or more cleaning brushes, the brushes can become "choked" as a result of the excessive amount of toner being delivered thereto. In an attempt to avoid choking, toner is typically removed from the bristles of each brush by way of "detoning". Established practices to detone fiber brushes include, but are not limited to: (a) overcoming electrostatic adhesion forces with a suitable air pressure differential, (b) knocking toner from fibers with a mechanical stop or a "flicker bar", (c) using biased detoning rolls to counter or oppose electrostatic forces greater than the adhesion forces and d) increasing brush speed so that the radial centrifugal force for toner detachment overcomes electrostatic adhesion force. Two other approaches to detoning are disclosed in the following references: US-A-4,172,303 and US-A-4,213,794 disclose a cleaning system with a cleaning brush that is adapted to remove toner from a photoconductive member as the brush is rotated about its central axis. The cleaning brush is in contact with a rotatable "comb", the comb including a rotatable shaft with bristles that engage the nap of the cleaning brush. The bristles of the comb are arranged in screw-type segments so that they traverse the nap of the cleaning nap as the rotatable shaft is rotated ana dislodge toner from the cleaning brush. The dislodged toner is directed by auger action toward a duct where it is removed by use of a vacuum source. The Xerox Disclosure Journal reference of Friday ("Friday Reference") - Vol. 1, No. 6 (1976), p.85 - teaches that matting, clumping or fusing of cleaning brush fibers can be alleviated by detoning a cleaning brush with a flicker bar with a comb-like member engaging the brush. Alternatively, the comb-like member can be used in conjunction with a conventional flicker bar. Cleaning of developer material from a photoreceptive surface can be further complicated when particulate and/or film forming additives, such as zinc stearate ("ZnSt") and/or aerosil (Si O 2 ) are added to the developer material. In highlight color printing, ZnSt and aerosil, among other additives, are added to color toner as flow, admix and charge control agents agents. It has been found that when ZnSt, for example, is used to control developer properties, deposition of these additives can occur on the photoreceptor and cause undesirable effects. For example, a CAD loss deletion can occur when a charged area passes through a DAD (Color) housing, thus resulting in partial discharge of the charged area and causing loss of image resolution. Furthermore, print quality defects can occur when a developed color image is passed through a CAD (Black) housing in that mechanical action of the circulating black "Mag" brush developer can physically shift (i. e. push) the color toner on the photoreceptor. This "image push" may be attributed to a reduction in friction (adhesion) between the color tone and the photoreceptor due to the presence of a ZnSt film. In the 4850 highlight color printer manufactured by Xerox® Corporation, some of the above-discussed undesirable effects attributed to the use of additives in the developer material is alleviated through use of a teflon ("teflon" is a trademark of E. I. Du Pont de Nemours & Co.) coated flicker bar in conjunction with a vacuum exhaust. The teflon coating of the flicker bar tribo-charges the bristles or fibers of the cleaning brush(es) positively. This tribo-charging has been found effective in promoting cross-mixing of in-coming black toner along the brush(es). This cross-mixing uniformly tones the brushes with black toner which inhibits additive filming of the photoreceptor in non-imaged or background areas. Cleaning of developer material from a photoreceptive surface can be even further complicated when fibers of the cleaning brush become matted. In particular, the fibers of an insulative cleaning brush are intended to function independently so that continuous cleaning action can be achieved across the breadth of the photoreceptor. Experience has shown, however, that the fibers can stick together and the brush can become matted. Such undesirable behavior can result in gaps in a desired cleaning zone so that residual toner and other debris escapes removal from the photoreceptor. Difficulties in cleaning can arise when a conventional brush is used to detone a cleaning brush. For example, when large quantities of toner are delivered to the cleaning station of a printing machine, as is often the case with the 4850 highlight color printer, the detoning brush can become clogged or choked readily. It would be desirable to provide a detoning device that is particularly suited for detoning a cleaning brush which removes relatively large amounts of toner from the photoreceptor. While the teflon-coated flicker bar has been found to be adequate in removing developer additives from a cleaning, under certain circumstances, the coated flicker bar does not remove sufficient levels of the developer additives from the cleaning brush bristles. Accordingly, problems resulting from insufficient removal of developer additives can arise. For example, use of the coated flicker bar is partially ineffective when high vacuum exhaust selectively depletes black toner from the brush fibers. Additionally, the flicker bar is ineffective if black toner is not used. While a special black tone protocol can be used to periodically coat the fibers, when the black toner developer is disabled, the additional time required to perform these protocols is inconvenient to the user of the printer. It has been found that scraping developer additives off the cleaning brush bristles with a comb, as suggested by the Friday Reference, is appropriate for developer additive removal, provided the comb is suitably configured. Unfortunately, the Friday Reference provides no teaching as to how a detoning comb should be configured to maximize developer additive removal. It would be desirable to provide a detoning comb which is configured to maximize developer additive removal. In accordance with one aspect of the present invention there is provided a cleaning apparatus for removing residual developer material remaining on a surface of a photoreceptor member of a printing machine, comprising: a movable cleaning brush having bristles extending therefrom and being positioned adjacent the surface so that, when said movable cleaning brush is moved, said bristles are brought into contact with the surface for removing the residual developer material therefrom; and a detoning device being positioned adjacent to said movable cleaning brush in a manner that permits said bristles to contact said detoning device as said movable cleaning brush is moved, characterised by said detoning device including a plurality of hook-like members which dislodge the residual developer material from said bristles as they contact said hook-like members. These and other aspects of the invention will become apparent from the following description, in conjunction with the accompanying drawings, in which: Figure 1 is a plot of photoreceptor potential versus exposure, for a tri-level electrostatic latent image; Figure 2 is a plot of photoreceptor potential representing particular single-pass highlight color latent image characteristics; Figure 3 is a schematic view of a printing machine with which the present invention can be employed; Figure 4 is a partial plan view of a photoreceptive belt used in the printing machine of Figure 3; Figure 5 is a schematic view of a control circuit used to control various components of the printing machine of Figure 3; Figure 6A is an elevational view of a cleaning brush being employed with a detoning device which uses a comb; Figure 6B is a plan view of the detoning device of Figure 6A; Figure 7 is a blown up, plan, partial view of the detoning device of Figure 6A with a cleaning brush bristle disposed between a pair of spaced teeth; Figure 8 is a partial, elevational view of the detoning arrangement of Figure 6A; Figure 9A is a plan view of another detoning device that can be used in the detoning arrangement of Figure 6B; Figure 9B is an exploded view of yet another detoning device that can be used in the detoning arrangement of Figure 6B; Figure 10A is an elevational view of the cleaning brush being employed with a detoning device which embodies one aspect of the present invention; Figure 10B is an partial, blown-up, isometric view of the detoning device of Figure 10A; and Figure 11 is an elevational view of another detoning device that can be used with the detoning arrangement of Figure 10A. Referring to Figures 1 and 2, the concept of tri-level highlight color imaging is described generally. For a photo-induced discharge curve ("PIDC") of Figure 2, V 0 represents the initial charge level, V ddp (V CAD ) the dark discharge potential (unexposed), V White , the white or background discharge level, and V c (V DAD ) the photoreceptor residual potential. In one example, nominal voltage magnitudes for V CAD , V White and V DAD are 788v, 423v and 123v, respectively. In highlight color applications, color discrimination in the development of the electrostatic latent image is achieved by passing the photoreceptor, with a latent image disposed thereon, through first and second developer housings and biasing the housings to voltages which are offset from the background voltage V White . In one illustrated embodiment, the second housing contains developer with positively charged black toner. Accordingly, the toner from the second housing is driven to the most highly charged (V ddp ) areas of the latent image by the electrostatic field between the photoreceptor and the development rolls in the second housing, the second housing development rolls being biased at V black bias (V bb ). The first housing contains negatively charged colored toner. Accordingly, the toner from the first housing is urged towards parts of the latent image at the residual potential, namely V DAD , by the electrostatic field existing between the photoreceptor and the development rolls of the first housing, the first housing rolls being biased to V color bias, (V cb ). In one example, nominal voltage magnitudes for V bb and V cb are 641v and 294v, respectively. Referring to Figure 3, a reproduction machine in which the present invention finds advantageous use employs a photoreceptor belt 10 having a charge retentive surface. Belt 10 moves in the direction of arrow 12 to advance successive portions of the belt sequentially through the various processing stations disposed about the path of movement thereof. A detailed description of the machine of Fig. 3 has been omitted from the present disclosure since the construction is well known in the art. Referring to Figure 4, in the preferred embodiment of the present invention, latent images from documents are formed respectively in document portions or zones of the charge retentive surface of the photoreceptor, each of which document zones is designated by the numeral 22. Areas interposed between the document zones 22, are referred to as interdocument zones, and are designated by the numeral 24. Referring again to Fig. 3, a pre-clean corona generating device 102 is provided for exposing the residual toner and contaminants (hereinafter, collectively referred to as toner) to positive charges to thereby shift the charge distribution thereon in a positive direction for more effective removal at cleaning station F. The cleaning station F further includes an electrically insulative, rotatably mounted cleaning member designated by the numeral 104. The member 104 is a fibrous brush in contact with the surface of the belt 10. The insulative brush is capable of being charged up during rotation, via triboelectric interaction with other cleaning members, for attracting toner(s) of the opposite polarity. Alternatively, the brush could be a conductive brush adapted to be biased for attracting toner(s) of the opposite polarity. A conductive brush suited for such cleaning is disclosed in US-A-4,819,026 to Lange et al. In another example, two brushes could be mounted in cleaning relationship relative to the surface of the belt 10 to achieve redundancy in cleaning. It is contemplated that residual toner remaining on the charge retentive surface of belt 10 after transfer will be reclaimed and returned to the developer station C by any one of several well known reclaim arrangements. Referring to Figure 5, a control circuit for use with the above-described xerographic engine is designated with the numeral 110. In the illustrated embodiment of Figure 5, the IRD 38, ESV1 40 and ESV2 54 are coupled with a machine controller 112 by way of an A/D converter 114, while the ESS 34, the patch generator 36 and the corona devices 64-66 and 102 are coupled with the controller 112 by way of a D/A converter 116. As will be appreciated by those skilled in the art, the machine controller 112 includes all of the appropriate circuitry for controlling the various devices coupled therewith and suitable memory for storing reference values corresponding to any measurements received from the ESV1, ESV2 or the IRD. In one embodiment the machine controller 112 could comprise a virtual machine control apparatus of the type disclosed in US-A-4,475,156 to Federico et al. Referring still to Figure 5, preselected current levels are respectively applied across the corona devices 64-66 and 102 during cycle-up or runtime to enable efficient transfer, detack and cleaning. That is, the respective applied current levels through the corona devices 64-65 are set to obtain optimal transfer, while the respective applied current levels through corona devices 66 and 102 are set to obtain optimal detack and cleaning. Referring to Figures 6A and 6B, a flicker bar, particularly suited for scraping a developer material additive, such as ZnSt and/or aerosil from the cleaning brush 104, is designated by the numeral 200. A vacuum exhaust system, represented by the box with the numeral 202, is preferably positioned over the flicker bar 200 for removing developer material, developer material additives and/or other debris removed from the cleaning brush with the flicker bar 200. In the illustrated embodiment of Figure 6B, the flicker bar 200 comprises a comb with a plurality of teeth 204 arranged along a common axis to define a plurality of uniform spaces 206. Additionally, the comb 200 is preferably coated with or constructed form a tribo-electrically inducing substance, such as teflon ("teflon" is a trademark of Du Pont de Nemours & Co), to promote cross-mixing of black toner along the cleaning brush bristles. It has been found that this cross-mixing inhibits additive filming in non-imaged and background areas of the photoreceptor. In practice, the comb 200 is superposed relative to the brush 104 so that portions of the brush bristles pass through the spaces 206 as the brush 104 is rotated. Referring to Figure 7, the teeth 204 are positioned in a manner which permits one bristle to be scraped by two adjacent teeth. In one example, the bristles have a circular transverse cross-sectional area and the width of each space 204 is approximately equal to the diameter of each bristles. Referring to Figures 6A and 8, the operation of the comb 200 is discussed in further detail. For a given bristle, its upper portion is moved into one of the spaces 206 and is engaged by a pair of the teeth 204. Referring specifically to Figure 8, as the bristle is moved away from the teeth 204, developer material additives, designated by the numeral 208, and some electrostatically attached toner designated by the numeral 210 is captured on an upper surface of the comb 200. In turn, the material captured on the comb upper surface is borne way by the vacuum exhaust system 202. A problem in comb design can arise as a result of variance in bristle dimensions. That is, for a given cleaning brush, the diameter of the bristles can vary, and among a group of similarly dimensioned brushes, the mean diameter can vary. Since the diameters tend to be relatively small--typically as small as 30.0µm--even minor variations in comb tooth spacing can read to ineffective detoning. This problem can be overcome by providing a comb with variable spacing. Referring to Figure 9A, an alternative embodiment of the comb 200 is designated by the numeral 200a. With the comb 200a, each of teeth 204 is tapered so that each spaces 206 has the appearance of a "V", as seen in a plan view. In operation, a bristle with a relatively larger diameter is engaged by a tooth pair near the opening of the V, and a bristle with a relatively smaller diameter is engaged near the vertex of the V. Referring to Figure 9B, another alternative embodiment of the comb 200 is designated by the numeral 200b. The comb 200b is a composite comb which includes a plurality of combs. While the comb 200b is shown as a composite of combs 200b-1 and 200b-2, it could comprise more than two combs without affecting the concept upon which the composite comb is based. Preferably, the spacing between the combs is such that a suitable upper portion of a bristle with a relatively smaller diameter can pass through spaces defined by both of combs 200b-1 and 200b-2. In operation, a given bristle either passes through comb 200b-1 and is scraped by comb 200b-2, or the given bristle is scraped by comb 200b-1 and is precluded from entering any of the spaces in the comb 200b-2. When images are developed in the document zones 22 (Figure 4), little developer material remains on the belt 10 subsequent to transfer so that cleaning of the belt 10 is obtained by adjusting the corona device 102 and the cleaning brush 104 appropriately. When images are developed in both the document zones 22 and the interdocument zones 24, however, a problem in cleaning can arise since the developed patch in each interdocument zone is not typically removed from the belt 10 prior to cleaning. The relatively high quantity of developer material on each developed patch, which is ultimately delivered to the cleaning station F, can result in clogging or choking of the cleaning station with the excessive amount of toner. It is believed that many known detoning arrangements are not capable of handling the amounts of toner that are delivered to a cleaning station as a result of cleaning developed patches of interdocument zones. Referring to Figures 10A and 10B, another detoning device, which is especially suited for facilitating removal of relatively large quantities of toner from the cleaning station F, is designated by the numeral 214. The detoning device 214 includes arrays of semi flexible or stiff bristles 216 which are mounted to a portion of the printing system by way of a substrate 218. In one example, the vacuum source 202 is mounted above the detoning device 214 for purposes of capturing particles which are dislodged from the cleaning brush 104. The detoning device 214 is positioned adjacent to the brush 104 in such a way that the fibers or bristles of the cleaning brush pass through the bristles of the detoning device so that particles adhering to the cleaning brush are dislodged from the cleaning brush. The bristles 216 are intended to interfere with and remove strongly adhering particles, from the brush 104, which are not typically removed from the fibers by normal or existing brush detoning procedures. The detoning device can be placed in tandem with normal flicker bars to further enhance fiber detone. In addition, the device can be insulative, or conductive and biased with a DC or AC voltage to optimize detone for a particular application. The detoning device 214 could likewise be made of material which satisfies triboelectric charging sequences suitable to enhance detone. It has been found, through experimentation that the bristles of the detoning device 214 need to penetrate into the cleaning brush nap only enough to detone the fiber tips of the cleaning brush 104 to a depth sufficient to maintain the cleaning function. It is envisioned that the number density of the detoning device bristles can be quite low, so long as the residence time of the cleaning fiber tips within the device is sufficient to effect detoning. The bristle arrays of the detoning device 214 should be sparse enough to enable the cleaning fiber tips to easily pass through the detoning device. Referring to Figure 10B, the structure of the detoning device bristles is shown at a microscopic level. Preferably, the detoning bristles are composed of a material referred to as Velcro ("Velcro" is a trademark of Velcro Industries B.V.). Microscopically the anchor part of Velcro appears as broken loops. Each of the loops appear uniformly broken to yield a straight bristle and a counterpart shaped like a "fish-hook". Each bristle is relatively stiff so as not to be deflected when in contact with the rotating cleaner fibers. In one example, the broken loops are arranged in a series of straight rows 1mm apart - center-to-center separation along the rows is ∼1mm. The length of the bristles may also be ∼1mm and the bristle diameter may be ∼0.1mm In the above embodiment, the detoning device 214 is shown as being mounted to a portion 220 of the reproduction machine; however, as shown in Figure 11, the detoning device 214 could be embodied in a rotating device, namely rotating brush 222. Preferably, the detoning brush 222 includes a plurality of the hook-like members 216 mounted to a core 224. It is believed that the rotating action of brush 222 can assist in detoning and further promote material throughput. Numerous features of the present invention will be appreciated by those skilled in the art: One feature of the disclosed embodiment resides in the use of a first detoning device, with hook-like members, the hook-like members facilitating the detoning of developer material from a cleaning brush. The first detoning device not only alleviates choking of developer material in a cleaning station, but is compatible with existing technology, promotes system reliability and has the potential of maximizing developer material throughput. Another feature of the disclosed embodiment is that the first detoning device is easy to fabricate and then use in its intended environment. In particular, the first detoning device is installed readily in the cleaning station. Moreover, after the first detoning device has reached the end of its useful life, it can be replaced easily. Yet another feature ot the disclosed embodiment resides in the use of a second detoning device comprising one or more combs each comb having a plurality of spaced teeth. In operation, the teeth serve to scrape developer material and developer material additives from bristles of the cleaning brush. In a first example, each pair of teeth is spaced in a manner which causes each bristle to be scraped singularly by a pair of teeth. In a second example, the bristles have varying cross sections, characterized by respective diameters, and the teeth are tapered, so that the spaces between the teeth vary in width. Accordingly, in this second example, the second detoning device is capable of scraping developer material and developer material additives from bristles of varying diameters. In a third example, the comb comprises a composite comb which is also capable of scraping developer material and developer material additives from bristles of varying diameters. As should be appreciated, the second detoning device permits maximization of developer material additive throughput and eliminates the need for lengthy and expensive materials modification. Additionally, the second detoning device provides a hardware solution to complex materials issues.

Claims: A cleaning apparatus for removing residual developer material remaining on a surface of a photoreceptor member (10) of a printing machine, comprising: a movable cleaning brush (104) having bristles extending therefrom and being positioned adjacent said surface so that, when said movable cleaning brush is moved, said bristles are brought into contact with the surface for removing the residual developer material therefrom; and a detoning device (214 ; 222) being positioned adjacent to said movable cleaning brush (104) in a manner that permits said bristles to contact said detoning device as said movable cleaning brush is moved, characterised by said detoning device (214) including a plurality of hook-like members (216) which dislodge the residual developer material from said bristles as they contact said hook-like members. The cleaning apparatus of claim 1, wherein said detoning device (214) further comprises a substrate (218), said hook-like members (216) being mounted on said substrate, and wherein said hook-like members (A) are substantially shorter than said bristles, (B) are arranged in rows with each bristle moving through a substantial portion of the rows, (C) comprise conductive hook-like members adapted to be electrically biased with an electrical signal to assist in removing the residual developer material from said movable cleaning member, and/or (D) comprise hook-like members adapted to be tribo-electrically charged for removing the residual developer material from said movable cleaning brush. The cleaning apparatus of claim 1 or 2, wherein said detoning device (214) is mounted to a portion of the printing machine so that said detoning device is stationary relative to said rotatable cleaning brush (104), the detoning device preferably being releasably mounted to the printing machine portion. The cleaning apparatus of claim 1, 2 or 3, wherein the detoning device (214) includes a detoning member which is separate from said plurality of hook-like members (216), said detoning member supplementing the removal of residual developer material from said movable cleaning brush. The cleaning apparatus of claim 1, 2 or 4, further comprising a vacuum source (202), positioned adjacent to said hook-like members (216), for removing the residual developer material therefrom. The apparatus of claim 1 or 2, or claim 4 or 5 when dependent thereon, wherein said movable cleaning brush (104) is rotatable; and said detoning device (214) is rotatable so that it can be rotated relative to said rotatable cleaning brush.

Inventors: BIGELOW RICHARD W, LUNDY DOUGALS A, BIGELOW, RICHARD W., LUNDY, DOUGALS A.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1994
Main classification: G03G21
IPC codes: G03G21